Alignment Tool

ABSTRACT

An alignment tool for connection to a work component. The alignment tool includes a body, a retention member that extends upward from the body, a clamp assembly spaced from the retention member and being connected to the body, a first reference surface that extends upward from the body and is located between the retention member and where the clamp assembly is connected to the body. The clamp assembly has a fastener that extends toward the retention member and past the first reference surface of the body, wherein the clamp assembly is movable t to draw a distal end of the fastener in a direction toward where the clamp assembly is connected to the body and the fastener is biased to move the distal end of the fastener toward the first reference surface.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No.15/748,089, filed Jan. 26, 2018, which claims the benefit of priority ofU.S. Provisional Patent Application Ser. No. 62/356,758, filed Jun. 30,2016 and PCT Application Serial No. PCT/US17/40056, filed Jun. 29, 2017,the disclosures of which are hereby incorporated by reference in theirentirety.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention generally relates to tools that provide temporaryor longer term connection to a work component to establish a precisiongage or guide, and more particularly a quick and accurate way toremovably join an alignment tool to a work component by usingcomplementary reference surfaces.

Discussion of the Prior Art

The alignment and connection of separate elements of tools, fixtures,and guide assemblies often relies on use of channels, such as in theform of T-shaped slots, commonly referred to as “T-slots”, in one ormore of the components to be connected for temporary or longer term use.This has been satisfactory for many uses, but has serious limitationswhen precision and sturdiness of the connection are required. A commonproblem with such prior art configurations relates to the inaccuracy ofthe alignment as a result of necessary manufacturing tolerances of thecomponents to be connected. In light of such component tolerances andthe means of connection, the current state of the art for achievingprecise alignment of temporary or longer term connected removablecomponents continues to involve multiple steps and the need to checkrelative positioning and make adjustments to account for misalignments.

For instance, step one generally involves bringing components to beconnected into close proximity and loosely connecting them withfastening means of a suitable type such as nuts and T-bolts that slidewithin the T-slots. Step two requires the application of a separateprecision gage along surfaces of the components to provide the alignmentguidance by positioning the components to be connected in the requiredrelative position they will assume when connected and while removing anyslack introduced by the fastening method and/or inherently presentbetween the components to be connected. Step three requires carefultightening of the fastening means, in an effort to avoid causing anyunintended displacement of the components relative to each other thatwould result in misalignment. This is necessary because tightening ofthe fastening means also can and often does introduce forces that tendto displace the components from their intended position. Step fourrequires verification to ensure the component relationship is stillpositioned accurately after tightening, with this check or inspectionrequiring further use of the separate precision gage or similar means.

This prior art process of connecting an alignment tool to a workcomponent often is used when connecting an alignment tool to a track sawrail. A track saw rail typically includes an elongated aluminumextrusion having various surfaces that permit attachment of the tracksaw rail to a table or to a work piece that may be a sheet material tobe cut, while providing a track along which a circular saw will slidevia a slidable mating saw base. Common surfaces provided by a track sawrail include surfaces defined by a T-slot in the bottom of the rail. TheT-slot structure permits traditional T-slot style connections as aprincipal means of alignment. Such traditional connections utilize anelement within the T-slot, such as a bolt or T-bolt with a threadedshaft extending from the head and through the open slot of the T-slot. Amating knob or nut would be used with the bolt or T-bolt to apply aclamping load to the opposed cantilevered side walls of the T-slot.Alternatively, a nut or T-nut may slide within the T-slot and a bolt mayextend through the open slot to apply the clamp load. The traditionalT-slot style connections suffer due to tolerances that permit even anelongated head on a T-bolt or an elongated T-nut to become misalignedwithin a T-slot. The connection is especially susceptible to this when auser introduces torque to the clamping knob, nut or bolt which tends totighten but also to move the element within the T-slot. To the extentthat the components may have shifted during tightening, the connectionthen must be loosened and the process must be repeated until theconnected components yield an intended combination in accordance withthe separate precision gage.

No practical means has been introduced in the prior art that eliminatesthe need for use of a secondary tool, such as a separate precision gage,to try to align components while making a connection, or the need tofurther verify proper alignment has been achieved. Also, it is common inthe prior art to periodically use the secondary tool to check forcontinued correct alignment, which is time consuming and bothersome.

SUMMARY OF THE INVENTION

The purpose and advantages of the present invention will be set forth inand apparent from the description and drawings that follow, as well aswill be learned by practice of the claimed subject matter. It is theobject of this invention to introduce an alignment tool and method ofusing the alignment tool that effectively provide a connection to a workcomponent which is precise as well as simple, and resistant tounintended change during use.

The present disclosure provides example alignment tools that utilize newstructures and methods of connection to a work component, which aredemonstrated for use with a work component, for example, in the form ofa track saw rail. The alignment tools take into account the structure ofthe elongated aluminum extrusion of the track saw rail and its varioussurfaces that permit attachment of the track saw rail to a table or workpiece, including the surfaces defined by the typical T-slot in thebottom of the track saw rail. However, unlike the prior art, theinventive alignment tools do not rely on traditional T-slot styleconnections as the principal means of alignment, due to theaforementioned disadvantages of such traditional connections.

In contrast, the examples in the present disclosure rely on mating orbringing into abutting engagement existing complementary referencesurfaces or guide surfaces, based on edges, features or shapes of theexample alignment tools and work component to be connected, with thecomplementary reference surfaces or guide surfaces being of knownaccuracy suitable for repeatable precise mating without need for use ofa secondary tool, such as a precision gage, to check the alignmentbetween the components. It will be appreciated that within thisdisclosure, a reference surface or guide surface that is to be used forabutting engagement may be defined, for example, by a broad flatsurface, or at least two spaced apart aligned features that could beprovided by any flat, curved, pointed or other surfaces, which togethermay be considered to define an elongated surface for purposes ofproviding abutting engagement. The example alignment tools also employ aclamp assembly that applies a force to simply draw the componentstogether at the complementary reference surfaces into abuttingengagement, and therefore, does not introduce any torque or other forcesthat would tend to displace the components from an otherwise perfectalignment, as intended. The clamp assembly also may compensate for anydimensional difference resulting from normal manufacturing tolerances orsimilar causes by employing a suitably strong clamp load, such as may beapplied by a biasing element, such as a spring between a fastener and abase, such as in a lever actuated clamp assembly having a latch as thefastener, or may be applied by other suitable clamp assembly structures,such as may include a threaded engagement, or the like, that is able todraw together the components by use of an alternative form of afastener.

In a first aspect, the present disclosure provides an alignment tool forconnection to a work component and for use in aligning the workcomponent with a work piece, wherein the work component has at least afirst reference surface that extends longitudinally in a firstdirection. The alignment tool includes a body having at least a firstreference surface that extends longitudinally in the first direction andhaving at least one work piece guide surface that extends in a seconddirection that is perpendicular to the at least first reference surface,and a clamp assembly connected to the body and extending in the seconddirection past the at least first reference surface of the body, whereinwhen the alignment tool is to be connected to the work component, theclamp assembly is movable to engage the work component and to drawtogether and hold in abutting engagement the first reference surface ofthe alignment tool and the first reference surface of the workcomponent.

In another aspect, the present disclosure provides an alignment tool forconnection to a work component and for use in aligning the workcomponent with a work piece, wherein the work component has at least afirst side wall surface that extends longitudinally in a firstdirection. The alignment tool includes a body having at least a firstguide surface that extends longitudinally in the first direction andhaving at least one work piece guide surface that extends in a seconddirection that is perpendicular to the at least one first guide surface,and a clamp assembly connected to the body and extending in the seconddirection past the at least first guide surface of the body, whereinwhen the alignment tool is to be connected to the work component, theclamp assembly is movable to engage the work component and to drawtogether and hold in abutting engagement the first guide surface of thealignment tool and the first side wall surface of the work component.

In a further aspect, the present disclosure provides a method ofconnecting an alignment tool to a work component for use in aligning thework component with a work piece, wherein the work component has atleast a first side wall surface extending longitudinally in a firstdirection and at least a T-shaped slot spaced apart from the at leastfirst side wall surface and extending longitudinally in the firstdirection. The method comprises the steps of: holding the alignment toolin a position adjacent an end of the work component, wherein thealignment tool includes a body having at least a first reference surfaceextending in the first direction, a retention element spaced from the atleast first reference surface, at least a first guide surface extendingin a second direction that is perpendicular to the first direction, anda clamp assembly connected to the body; moving the alignment tool towardthe work component so as to insert the retention element into theT-shaped slot that is spaced from the at least first side wall surfaceof the work component; moving the at least first reference surface ofthe alignment tool into a position opposite the first side wall surfaceof the work component; extending a fastener of the clamp assembly in thesecond direction beyond the first side wall surface of the workcomponent; moving the clamp assembly to engage the first side wallsurface of the work component and to draw together and hold in abuttingengagement the at least first reference surface of the alignment tooland the first side wall surface of the work component.

As above noted, the example alignment tools and example methods ofassembling an alignment tool to a work component of this disclosureprovide several advantageous features. The example alignment tools andmethods provide the ability to quickly and conveniently connect thealignment tool to a work component, without need to use a separate gageto check the accuracy of the alignment between the two components, or touse any tools. Additionally, the clamp assembly holds the two componentstogether firmly and makes the connection highly resistant to unintendedmisalignment during handling of the connected components, which may beaided by a biasing element. A quick and firm connection of the twocomponents is provided.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and provided forpurposes of explanation only, and are not restrictive of the subjectmatter claimed. Further features and objects of the present disclosurewill become more fully apparent in the following description of thepreferred embodiments and from the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

In describing the preferred embodiments, reference is made to theaccompanying drawing figures wherein like parts have like referencenumerals, and wherein:

FIG. 1 is a top view of a first example alignment tool removablyconnected to a work component in the form of a track saw rail proximatea first end of track saw rail;

FIG. 2 is a perspective end view of the first example alignment toolremovably connected to the work component of FIG. 1;

FIG. 3 is a perspective top view of the first example alignment tool ofFIG. 1, with the clamp assembly in a closed position;

FIG. 4 is a perspective top view of the first example alignment tool ofFIG. 1, with the clamp assembly in an open position, ready for slidableintroduction to the work component;

FIG. 5 is a perspective bottom view of the first example alignment toolremovably connected to the work component of FIG. 1 and positionedrelative to a work piece with a portion of a clamp passing through aclamp receiving notch;

FIG. 6 is a top view of a second example alignment tool removablyconnected to a work component in the form of a track saw rail in a firstposition proximate a first end of the track saw rail, and shown inphantom in a second position proximate a second, opposite end of thetrack saw rail;

FIG. 7 is a perspective end view of the second example alignment toolremovably connected to the work component of FIG. 6;

FIG. 8A is a perspective top view of the second example alignment toolof FIG. 6, with the clamp assembly in a closed position;

FIG. 8B is a perspective exploded view of a retention feature on thesecond example alignment tool of FIG. 6;

FIG. 9 is a perspective top view of the second example alignment tool ofFIG. 6, with the clamp assembly in an open position, ready for slidableintroduction to the work component;

FIG. 10 is a perspective bottom view of the second example alignmenttool removably connected to the work component of FIG. 6 and positionedrelative to a work piece with a portion of a clamp passing through aclamp receiving notch.

It should be understood that the drawings are not to scale. While somemechanical details of example alignment tools, including other plan andsection views of the examples shown and of examples that may havealternative configurations have not been included, such details areconsidered well within the comprehension of those of ordinary skill inthe art in light of the present disclosure. It also should be understoodthat the present invention is not limited to the example embodimentsillustrated.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

For the following defined terms, these definitions shall be applied,unless a different definition is given in the claims or elsewhere inthis disclosure. As used in this disclosure and the claims, the singularforms “a”, “an”, and “the” include plural referents unless the contentclearly dictates otherwise. As used in this disclosure and the claims,the term “or” is generally employed in its sense including “and/or”unless the content clearly dictates otherwise.

Referring generally to FIGS. 1-10, it will be appreciated that alignmenttools of the present disclosure generally may be embodied withinnumerous configurations, and may be used in various ways to enhance theconvenience of users. Indeed, while acknowledging that all of theexample configurations of alignment tools need not be shown herein,examples are provided to better demonstrate that a variety ofconfigurations and methods of use are contemplated.

Turning to a first example embodiment of an alignment tool 10 shown inFIGS. 1-5, it will be appreciated that the alignment tool 10 and a workcomponent 12 to which it will be connected may employ either existing orpurpose made suitable complementary mating reference surfaces that arebased on edges, features or shapes of the respective components. Asnoted previously, such complementary reference surfaces or guidesurfaces that are to be used for abutting engagement may be defined, forexample, by a broad flat surface, or at least two spaced apart alignedfeatures that could be provided by any flat, curved, pointed or othersurfaces, which together may be considered to define an elongatedsurface for purposes of providing abutting engagement, and which may beof known accuracy suitable for repeatable precise mating without needfor use of a secondary tool.

One possible application is shown in the first example embodiment of thealignment tool 10, which may be removably connected to the workcomponent 12. In this example, the work component 12 is shown as a tracksaw rail, which essentially is a metal extrusion in the form of a trackfor guiding power tools, such as a track saw. For example, the track 12may be used with a handheld circular saw for cutting a work piece, suchas a flat sheet material, which may be plywood, pressboard or othermaterials. In the particular configuration shown, the work component 12may be used with a circular saw designed to be used with the track.Thus, the saw may incorporate or accommodate a base that is adapted forprecision sliding movement along the extruded track 12.

In this particular example, among other shapes and surfaces, theextruded track of the work component 12 includes a first T-slot 20,which is longitudinally extending and upward facing. The T-slot 20features a channel 22 having a first side wall 24 and a second side wall26. The upper ends of the side walls 24, 26 include lips 24′, 26′ thatextend toward each other and the opposed lips 24′, 26′ define an openslot 28 therebetween. The work component 12 also includes a secondT-slot 30, which is longitudinally extending and downward facing. TheT-slot 30 is parallel to the T-slot 20, and thus parallel to and spacedapart from the first side wall 24. The T-slot 30 features a channel 32having a first side wall 34 and a second side wall 36. The lower ends ofthe side walls 34, 36 include lips 34′, 36′ that extend toward eachother and the opposed lips 34′, 36′ define an open slot 38 therebetween.

The work component 12 includes reference surfaces that may be used whenconnecting an alignment tool 10 to the work component 12. The examplealignment tool 10 may be configured to be connected in a preciselyaligned relationship with the work component 12 via use of complementaryreference surfaces. The upward facing first T-slot 20 is located alongan outer edge of the work component 12, such that the first side wall 24includes an outer surface, which may be referred to as a first side wallsurface or first reference surface 40. The first side wall surface orfirst reference surface 40 of the work component 12 extendslongitudinally in a first direction.

The bottom of the work component 12 provides a second reference surface42, which is perpendicular to the first side wall surface or firstreference surface 40 of the work component 12. The downward facingsecond T-slot 30 is open along the bottom of the work component 12 andlocated along a central region of the work component 12, spaced apartfrom the first side wall 24. The T-slot 30 also extends longitudinallyin the first direction. For purposes of the present disclosure, theupward facing surface of the lips 34′, 36′, which are within the T-slot30, collectively present a third reference surface 44 of the workcomponent 12. An inner surface of the first side wall 24 presents afourth reference surface 46 of the work component 12. It will beappreciated that each reference surface of the work component 12 extendslongitudinally along at least a portion of the length of the workcomponent 12 and may extend in a continuous or segmented manner, orotherwise may be defined by at least two spaced apart features orportions.

The alignment tool 10 is configured to achieve precise alignment withthe work component 12 via abutting complementary reference surfaces,while also providing one or more guide surfaces for abutting a workpiece or other object to be cut or otherwise positioned by use of thealignment tool. The alignment tool 10 includes a body 50 that may beconstructed for example of machined aluminum, but it will be appreciatedthat the body may be constructed of any suitable rigid material, whethermachined, cast or molded. In this example, an outer perimeter of thebody 50 includes a first side wall 52, second side wall 54, third sidewall 55, fourth side wall 56 and fifth side wall 58. It will beappreciated that other configurations may be provided with fewer or moreside walls, and the side walls may provide guide surfaces. For example,the first side wall 52 presents a first work piece guide surface GS1,while the second side wall 54 may present a second work piece guidesurface GS2. It will be appreciated that a guide surface may extendalong at least a portion of a side wall or other surface of the body 50and may extend in a continuous or segmented manner, or otherwise may bedefined by at least two spaced apart features or portions.

The body 50 of the alignment tool 10 also includes a first guide surfaceor first reference surface 60 provided by an upstanding rib or wall 62that extends longitudinally in the first direction, and is located alonga central region of the body 50. It will be appreciated that the firstwork piece guide surface GS1 extends in a second direction that isperpendicular to the first guide surface or first reference surface 60.It also will be appreciated that the first guide surface or firstreference surface 60 also extends in an upright direction.

The body 50 further includes a second guide surface or second referencesurface 64, which is upward facing, and therefore, perpendicular to thefirst guide surface or first reference surface 60. The second guidesurface or second reference surface 64 provides a landing against whichthe work component 12 may rest. Although they are shown as continuouselongated surfaces, it will be appreciated that each of the first andsecond reference surfaces 60, 64 of the alignment tool 10 may extend ina continuous or segmented manner, or otherwise may be defined by atleast two spaced apart features or portions.

The alignment tool 10 further includes a clamp assembly 70. The clampassembly 70 is configured to be mounted to the body 50 of the alignmenttool 10 and to extend in the second direction past at least the firstguide surface or first reference surface 60 of the alignment tool 10.The example clamp assembly 70 includes a base 72 that is connected tothe body 50, such as by mechanical anchors 74 in the form of bolts orrivets, or by other suitable methods of connection. In this example, theclamp assembly 70 also includes a fastener 76 in the form of a latch, alever 78, and biasing element 80 that is connected to the base 72, lever78 and latch 76. The fastener or latch 76, lever 78 and biasing element80 are constructed and connected to permit the lever 78 to operate thelatch 76, under the influence of the bias element 80.

The fastener or latch 76 extends in the second direction past the firstguide surface or first reference surface 60 of the alignment tool 10, aswell as past the first side wall surface or first reference surface 40of the work component 12. This permits that fastener or latch 76 tocapture the work component 12. More particularly, the latch 76 includesa flange 82 at the distal end 84 of the latch 76. It will be appreciatedthat, as the latch 76 extends in the second direction, perpendicular toand across the first guide surface or first reference surface 60 of thealignment tool 10, it also extends parallel to the work piece guidesurface GS1. Accordingly, when the lever 78 is pivoted upward, the latch76 moves to extend further from the base 72, which allows the latch 76to pivot to raise the flange 82 at the distal end 84, to assume the openposition shown in FIG. 4. The pivotal positions of the lever 78 andlatch 76 are configured to have an over-center movement to a closedposition, which utilizes the biasing element 80, in the form of aspring, so that when the lever 78 is pivoted downward toward the closedposition shown in FIGS. 1-3, the flange 82 of the latch 76 has beendrawn closer toward the base 72 of the clamp assembly 70.

FIG. 2 is particularly instructive regarding the connection of thealignment tool 10 and work component 12. FIG. 2 shows the first guidesurface or first reference surface 60 of the alignment tool 10 has beenbrought into abutting engagement with the first side wall surface orfirst reference surface 40 provided by the outer surface of the firstside wall 24 of the work component 12. The second reference surface 64of the alignment tool 10 also has been brought into abutting engagementwith the second reference surface of 42 of the work component 12. Theflange 82 at the distal end 84 of the fastener or latch 76 also has beenpositioned to extend past the first guide surface or first referencesurface 60 of the alignment tool 10 and past the first side wall surfaceor first reference surface 40 of the work component 12, and has beenpivoted downward, so as to engage the lip 24′ at the third referencesurface 44 on the inner surface of the first side wall 24 of the workcomponent 12. With the lever 78 pivoted downward to a closed position,the fastener or latch 76 and its flange 82 are pulled toward the base 72until the first guide surface or first reference surface 60 of thealignment tool 10 is securely abutting the first side wall surface orfirst reference surface 40 of the work component 12.

In this example, the over-center travel of the lever 78 causes it toautomatically be retained in the closed position, until a deliberateforce is applied to move the lever 78 by pivoting to an open position.In addition, the biasing element 80 biases the latch 76 toward the base72, which additionally aids in maintaining a firm connection between thealignment tool 10 and work component 12. Thus, actuation of the lever 78can quickly and conveniently draw the two components together intoabutting engagement of the respective first reference surfaces that willassure a perfect alignment of the alignment tool 10 and work component12, without need of other tools, or readjustment, and without need tocheck the alignment with a separate gage. It will be appreciated,however, that the clamp assembly 70 may have a different structure andapplication of a fastener, alternatively to fastener 76, which could beutilized without tools, or with tools but in a simple manner that doesnot require use of a second gage or rechecking of the alignment achievedby use of the abutting engagement of the respective first referencesurfaces.

Thus, the example clamp assembly 70 is configured to apply a continuousforce when in a closed or latched position, to keep the two componentssecurely aligned and in the same position relative to each other, aslong as the user wishes and without any additional attention orverification. The clamp assembly 70 may be constructed of steel, carbonfiber or other materials of suitable strength in such a manner that theforce applied is self-regulating and independent of normal variations inthe interfacing dimensions of the mating components. This may beachieved through the use of latch components which are elastic enough tobe pulled tight over center with the resulting deflection of the steelor similar strong but flexible spring material producing the requiredclamping force to be achieved and maintained without deforming thefastener or latch 76, or side wall 24, through repeated usage cycles. Itwill be appreciated that the clamp assembly may have alternatestructures to generate relative movement of a fastener, and may maintainits position via other configurations than an over-center lever andlatch.

In the example shown, the alignment and security of the connection maybe enhanced by an additional engagement of reference surfaces betweenthe two components. For instance, additional reference surfaces mayprevent forces from tending to rotate, twist or otherwise move thealignment tool 10 relative to the work component 12 in a manner thatotherwise might defeat the alignment function. The engagement of suchadditional surfaces or features need not be particularly accurate butwill still act to limit unintended relative movement of the matedcomponents to a degree which will not allow the function of the clampassembly 70 to be defeated. For example, the alignment tool 10 is shownwith an upstanding retention element 90, which in this example isT-shaped, extends in an upright direction, and is suitably sized to beslidably received within the channel 32 and slot 38 of the downwardfacing T-slot 30 of the work component 12. A T-slot is commonly found inextrusions of typical guide tracks and similar work components. Thisfeature is intentionally relatively loose fitting, so as not tointerfere with zero-clearance mating of the respective first referencesurfaces 60, 40 of the alignment tool 10 and work component 12.

It will be appreciated that once the retention element 90 is received bythe downward facing T-slot 30, the first guide surface or firstreference surface 60 of the alignment tool 10 is effectivelyself-aligning with the first reference surface 40 of the work component12. The underside of the extensions provided by the T-shape of theretention element 90 present a collective third reference surface 92 ofthe alignment tool 10. It will be appreciated that when the alignmenttool 10 is to be connected to the work component 12, the third referencesurface 92 of the alignment tool 10 engages the third reference surface44 of the work component 12. Indeed, the retention element 90 may beuseful in initially aligning the alignment tool 10 with the workcomponent 12, but also may assist in maintaining connection of the twocomponents by preventing rotation of the work component 12 relative toor about the first reference surface 60 of the alignment tool 10. Thus,if the clamp assembly 70 creates any force that would act to draw thetop of the first side wall 24 over the wall 62 of the alignment tool,such pivoting or rotation of the work component 12 will be prevented bythe engagement of the respective third reference surfaces 44, 92. Thisaid to retaining the connection between the two components 10, 12 isconvenient and highly effective, even though the retention element 90simply may be sized to be slidable within the downward facing T-slot 30.

For added convenience, the body 50 of the alignment tool 10 may includea notch 94 to accommodate usage of a clamp 96. The notch 94 permits thebar 98 of the clamp 96 to apply a clamp load more directly through thearea to be clamped. The head of the clamp 96 may be received by thedownward facing T-slot 30 and the clamp 96 may be used to hold the workcomponent 12 in place relative to a work piece. Added convenience ingrasping the alignment tool 10 also may be had by inclusion of openings93 and 95 in the body 50, but it will be appreciated that alternativeopening shapes and numbers of openings may be utilized.

As will be appreciated by the above description, the clamp assembly 70permits rapid connection of the alignment tool 10 to the work component12, as a user merely must bring the respective first reference surfaces60, 40 into abutting relationship, move the latch 76 to engage the workcomponent 12 at the first side wall 24, and then move the lever 78 fromthe unlatched to the latched position to draw together and hold inabutting engagement the first guide surface or first reference surface60 of the alignment tool 10 and the first wall surface or firstreference surface 40 of the work component 12. Abutting engagement ofthe respective second reference surfaces 62, 42 may assist in aligningthe components 10 and 12, as may be the case with use of the retentionelement 90 to engage respective third reference surfaces 44, 92. Thebiasing element 80 ensures a firm connection is provided by the latchassembly 70 of the alignment tool 10 and the side wall 24 of the workcomponent 12. It will be appreciated that the biasing element may beprovided by means of a different configuration, and furtheralternatively that the lever and latch or fastener may be configured ina manner that reduces the need for a biasing element, or wherein one orboth of the lever or latch is configured to deflect in a manner thatprovides some resilience without a separate biasing element.

Given that the first guide surface or first reference surface 60 isperpendicular to the first work piece guide surface GS1 of the alignmenttool 10, the positive abutting engagement of the first and secondreference surfaces 60, 64 of the alignment tool 10 with the respectivefirst and second reference surfaces 40, 42 of the work component 12 willnecessarily result in the extruded track of the work component 12 beingprecisely perpendicular to the first work piece guide surface GS1. Thealignment tool 10 and its first work piece guide surface GS1 also extendbeneath the track 12, so as to provide an elongated first work pieceguide surface GS1 for greater accuracy. These features ensure that whenthe first work piece guide surface GS1 is placed against an edge of awork piece, the work component 12 will be precisely perpendicular to thework piece, so as to provide precise alignment and cutting of the workpiece. In addition, the over-center movement of the lever 78 to theclosed position effectively avoids having to account for the problematicinfluences in the prior art, such as tolerances or movements related topositioning or torque applied to fasteners, or loosening of the twocomponents during use, the need to use a separate gage to check andrecheck their alignment, etc. Also, it will be appreciated that thesecond work piece guide surface GS2 alternatively may be placed againstthe edge of the work piece to make a cut at the precise preselectedangle of the second work piece guide surface GS2.

It will be appreciated that the first example alignment tool 10 of thepresent disclosure provides for a method of connecting an alignment tool10 to a work component 12 for use in aligning the work component 12 witha work piece, wherein the work component 12 has at least a first sidewall surface 40 extending longitudinally in a first direction and atleast a T-shaped slot 30 spaced apart from the at least first side wallsurface 40 and extending longitudinally in the first direction. Themethod comprises the steps of: holding the alignment tool 10 in aposition adjacent an end of the work component 12, wherein the alignmenttool 10 includes a body 50 having at least a first reference surface 60extending in the first direction, a retention element 90 spaced from theat least first reference surface 60, at least a first guide surface GS1extending in a second direction that is perpendicular to the firstdirection, and a clamp assembly 70 connected to the body 50; moving thealignment tool 10 toward the work component 12 so as to insert theretention element 90 into the T-shaped slot 30 that is spaced from theat least first side wall surface 40 of the work component 12; moving theat least first reference surface 60 of the alignment tool 10 into aposition opposite the first side wall surface 40 of the work component12; extending a fastener 76 of the clamp assembly 70 in the seconddirection beyond the first side wall surface 40 of the work component12; moving the clamp assembly 70 to engage the first side wall surface40 of the work component 12 and to draw together and hold in abuttingengagement the at least first reference surface 60 of the alignment tool10 and the first side wall surface 40 of the work component 12.

Turning now to a second example embodiment of an alignment tool 110,shown in FIGS. 6-10. It will be appreciated that the second exampleshares some features with the first example alignment tool 10, butdiffers in a few respects that are evident when showing the alignmenttool 110 for use with the above-referenced work component 12. However,as with the first example alignment tool 10, it will be appreciated thatthe second example alignment tool 110 may be used with alternative workcomponents and may be configured in alternative ways. For ease ofcomprehension, reference numerals used in the description of the firstexample also will be used with the second example for features incommon.

Similar to the first example, the second example alignment tool 110 isconfigured to achieve precise alignment with the work component 12 viaabutting complementary reference surfaces, while also providing one ormore guide surfaces for abutting a work piece or other object to be cutor otherwise positioned by use of the alignment tool. However, thealignment tool 110 includes a body 150 that advantageously may be usedwith the work component 12 at either end of the work piece because ithas two opposed, parallel elongated work piece guide surfaces. The body150 may be constructed of similar materials and in a similar way to thebody 50 of the first example. In the second example, an outer perimeterof the body 150 includes a first side wall 152, second side wall 154,third side wall 155, fourth side wall 156 and fifth side wall 158. Itwill be appreciated that other configurations may be provided with feweror more side walls, and the side walls may provide guide surfaces. Forexample, the first side wall 152 presents a first work piece guidesurface GS1′, while the fourth side wall 156 presents a second workpiece guide surface GS2′ that faces in an opposite direction and isparallel to the first work piece guide surface GS1′. It will beappreciated that a guide surface may extend along at least a portion ofa side wall or other surface of the body 150 and may extend in acontinuous or segmented manner, or otherwise may be defined by at leasttwo spaced apart features or portions.

Similar to the first example, the body 150 of the alignment tool 110also includes a first guide surface or first reference surface 160provided by an upstanding rib or wall 162 that extends longitudinally inthe first direction, and is located along a central region of the body150. It will be appreciated that the first guide surface or firstreference surface 160 and wall 162 are taller than the respectivesurface 60 and wall 62 of the first example. The added height will tendto provide a more complete backstop or support for the wall 24 of thework component 12, which advantageously may help to avoid potentialdeformation of the wall 24 when repeatedly subjected to a clamping load.It also will be appreciated that the first work piece guide surface GS1′extends in a second direction that is perpendicular to the first guidesurface or first reference surface 160, and that the first guide surfaceor first reference surface 160 extends in an upright direction.

In addition, similar to the first example, the body 150 further includesa second guide surface or second reference surface 164, which is upwardfacing, and therefore, perpendicular to the first guide surface or firstreference surface 160. The second guide surface or second referencesurface 164 provides a landing against which the work component 12 mayrest. Although they are shown as continuous elongated surfaces, it willbe appreciated that, similarly to the first example, each of the firstand second reference surfaces 160, 164 of the alignment tool 110 mayextend in a continuous or segmented manner, or otherwise may be definedby at least two spaced apart features or portions. Indeed, the firstguide surface or first reference surface 160 of the second exampleactually includes two spaced apart portions 160′ at its ends that areparallel to each other and shown as roughly ½″ long, with an elongatedwall extending between them but featuring a maximum recess or relief ofroughly 0.005″ from the surface 160 defined by the parallel portions.This alternative first guide surface or first reference surface 160 witha centrally located relief advantageously ensures that the two spacedapart portions 160′ are utilized to effectively define the one desiredreference surface for abutting engagement with the work component 12.This configuration for first guide surface or first reference surface160 may improve the ability to ensure precise abutting engagement with afirst reference surface 40 of a work component 12, even if the wall 24of work component 12 happens to have some minor deformation, such as asmall dent.

The alignment tool 110 further includes the clamp assembly 70 of thefirst example alignment tool 10, other than a lever 178 that has aslightly different shape than lever 78, but which functions in the sameway. Thus, the clamp assembly 70 of the second example alignment tool110 is configured to be mounted to the body 150 and to extend in thesecond direction past at least the first guide surface or firstreference surface 160 of the alignment tool 110. The clamp assembly 70includes a base 72 that is connected to the body 150. However, in thesecond example, the base 72 is connected to the body 150 at a heightthat is lower relative to the second reference surface 164 or to thebottom of the rib or wall 162, when compared to the first examplealignment tool 10. This effectively lowers the clamp assembly 70relative to the bottom of the work component 12, and therebyadvantageously slightly repositions the pulling force of the clampassembly 70 to reduce the tendency to introduce a force that might tendto cause rotation of the work component 12 about the first guide surfaceor first reference surface 160 of the alignment tool 110. The clampassembly 70 also includes a fastener 76 in the form of a latch, a lever178, and biasing element 80 that is connected to the base 72, lever 78and latch 76. The fastener or latch 76, lever 178 and biasing element 80are constructed and connected to permit the lever 178 to operate thelatch 76, under the influence of the bias element 80.

As with the first example, the fastener or latch 76 extends in thesecond direction past the first guide surface or first reference surface160 of the alignment tool 110, as well as past the first side wallsurface or first reference surface 40 of the work component 12. This isso that that fastener or latch 76 can capture the work component 12,such as via the flange 82 at the distal end 84 of the latch 76. It willbe appreciated that, as the latch 76 extends in the second direction,perpendicular to and across the first guide surface or first referencesurface 160 of the alignment tool 110, it also is extending parallel tothe respective first work piece guide surface GS1′ and second work pieceguide surface GS2′. Accordingly, when the lever 178 is pivoted upward,the latch 76 moves to extend further from the base 72, which allows thelatch 76 to pivot to raise the flange 82 at the distal end 84 of thelatch 76 to the open position shown in FIG. 9. The pivotal positions ofthe lever 178 and latch 76 are configured to have an over-centermovement to a closed position, which utilizes the biasing element 80, inthe form of a spring, so that when the lever 178 is pivoted downwardtoward the closed position shown in FIGS. 6-8A, the flange 82 of thelatch 76 has been drawn closer toward the base 72 of the clamp assembly70. As described with respect to the first example, the clamp assembly70 may be constructed of steel, carbon fiber or other materials ofsuitable strength in such a manner that the force applied isself-regulating and independent of normal variations in the interfacingdimensions of the mating components. This may be achieved through theuse of a biasing element and/or use of latch components which areelastic enough to be pulled tight over center with the resultingdeflection of the steel or similar strong but flexible spring materialproducing the required clamping force to be achieved and maintainedwithout deforming the fastener or latch 76, or side wall 24, throughrepeated usage cycles. It will be appreciated that the clamp assemblymay have alternate structures to generate relative movement of afastener, and may maintain its position via other configurations than anover-center lever and latch.

FIG. 7 is particularly instructive regarding the connection of thealignment tool 110 and work component 12. FIG. 7 shows the first guidesurface or first reference surface 160 of the alignment tool 110 hasbeen brought into abutting engagement with the first side wall surfaceor first reference surface 40 provided by the outer surface of the firstside wall 24 of the work component 12. The second reference surface 164of the alignment tool 110 also has been brought into abutting engagementwith the second reference surface of 42 of the work component 12. Theflange 82 at the distal end 84 of the fastener or latch 76 also has beenpositioned to extend past the first guide surface or first referencesurface 160 of the alignment tool 110 and past the first side wallsurface or first reference surface 40 of the work component 12, and hasbeen pivoted downward, so as to engage the lip 24′ at the thirdreference surface 44 on the inner surface of the first side wall 24 ofthe work component 12. With the lever 178 pivoted downward to a closedposition, the fastener or latch 76 and its flange 82 are pulled towardthe base 72 until the first guide surface or first reference surface 160of the alignment tool 110 is securely abutting the first side wallsurface or first reference surface 40 of the work component 12, with thefirst guide surface or first reference surface 160 defined by theparallel spaced apart portions 160′, and depending on the force appliedby the clamp assembly 70, the first side wall surface or first referencesurface 40 of the work component 12 may engage the recessed portionbetween the portions 160′.

As in the first example, the over-center travel of the lever 178 of thesecond example causes it to automatically be retained in the closedposition, until a deliberate force is applied to move the lever 178 bypivoting to an open position. Also, the biasing element 80 biases thelatch 76 toward the base 72, which additionally aids in maintaining afirm connection between the alignment tool 110 and work component 12.Thus, the two components can be quickly and conveniently drawn togetherinto abutting engagement of the respective first reference surfaces 160,40 that will assure precise and secure alignment of the alignment tool110 and work component 12. As noted with respect to the first example,while this engagement is achievable without need of other tools or tocheck the alignment with a separate gage, an alternative clamp assemblymay be used while still taking advantage of the abutting engagementbetween the respective first reference surfaces. Thus, the example clampassembly 70 is configured to achieve a similar connection to thatdescribed with respect to the first example and may be constructed ofsimilar materials to those previously discussed so as to produce therequired clamping force to be achieved and maintained without deformingthe fastener or latch 76, or side wall 24, through repeated usagecycles. As described, the structures of the body 150 of the secondexample also included a few advantageous modifications that will impactthe support for the work component 12 and the application of the forceof the clamp assembly.

As with the first example, the security of the connection for the secondexample alignment tool 110 may be enhanced by an additional engagementof reference surfaces between the two components. For example, thealignment tool 110 is shown with an upstanding retention element 190,which in this example would be T-shaped in cross-section, but also maybe described as providing a button configuration. As seen in FIGS. 7, 8Aand 8B, the retention element 190 extends in an upright directionsimilar to the earlier example retention element 90, but has a button ordisc shape 190′ that is suitably sized to be slidably received withinthe channel 32, while having a post 190″ that is suitably sized to beslidably received within the slot 38 of the downward facing T-slot 30 ofthe work component 12. The post 190″ also receives a fastener, such as aflat head screw 191, which extends through a slightly elongated hole 165in the body 150. The post 190″ may include a threaded passage to receivethe fastener 191. The fastener 191 may be tightened completely to holdthe retention element 190 in a set position, but it may advantageouslybe used with a thread locking compound or nylon locking element toretain the fastener in a chosen position relative to the post 190″,without exerting a clamping load. This configuration allows theconnection of the fastener 191 to the post 190″ to be established in amanner that permits the fastener 191 to move within the hole 165 towardand away from the first guide surface or first reference surface 160, asmay be needed when engaging the T-slot 30 in the work component 12.Thus, this configuration of retention element 190 provides analternative that still may be considered to be T-shaped butadvantageously is self-aligning relative to the work component 12, whichcan account for slight variations in the distance between the outer wall24 and the T-slot 30, while effectively providing draft angles for easyinsertion into the T-slot 30. Accordingly, this is another way tointentionally provide a relatively loose fitting retention element, soas to self-align but not interfere with zero-clearance mating of therespective first reference surfaces 160, 40 of the alignment tool 110and work component 12.

It will be appreciated that once the retention element 190 is receivedby the downward facing T-slot 30, the underside of the button 190′provided by the T-shape of the retention element 190 presents acollective third reference surface 192 of the alignment tool 110. Itfurther will be appreciated that when the alignment tool 110 is to beconnected to the work component 12, the third reference surface 192 ofthe alignment tool 110 engages the third reference surface 44 of thework component 12. Indeed, the retention element 190 may be useful ininitially aligning the alignment tool 110 with the work component 12,but also may assist in maintaining connection of the two components bypreventing rotation of the work component 12 relative to or about thefirst reference surface 60 of the alignment tool 110. Thus, if the clampassembly 70 creates any force that would act to draw the top of thefirst side wall 24 over the wall 62 of the alignment tool, such pivotingor rotation of the work component 12 will be prevented by the engagementof the third reference surfaces 44, 192. This aid to retaining theconnection between the two components 110, 12 is convenient and highlyeffective, even though the retention element 190 may be self-aligning bybeing sized to be slidable within the downward facing T-slot 30 and/orconnected to the body 150 at a slightly elongated hole 165 that permitsmovement of the fastener 191 of the retention element 190.

Similar to the body 50 of the alignment tool 10 of the first example,the body 150 of the alignment tool 110 of the second example may includenotches 194 for added convenience in accommodating usage of a clamp 96.The notches 194 extend inward from the respective first and second workpiece guide surfaces GS1′, GS2′ to permit the bar 98 of the clamp 96 toapply a clamp load more directly through the area to be clamped. As withthe first example, the head of the clamp 96 may be received by thedownward facing T-slot 30 and the clamp 96 may be used to hold the workcomponent 12 in place relative to a work piece. Added convenience ingrasping the alignment tool 110 also may be had by inclusion of openings193 and 195 in the body 150, but it will be appreciated that alternativeopening shapes and numbers of openings may be utilized.

In accordance with FIG. 6, it will be appreciated that the mainadvantage of the second example alignment tool 110 relative to the firstexample alignment tool 10 is that the alignment tool 110 may be locatedat either end of a work piece because it can slide along the workcomponent 12 and be positioned either proximally or distally (shown indashed lines), so as to present either the first work piece guidesurface GS1′ along a proximal edge of a work piece, or present thesecond work piece guide surface GS2′ along a distal edge of a work piece(work piece not shown).

As will be appreciated by the above description, the clamp assembly 70permits rapid connection of the alignment tool 110 to the work component12, as a user merely must bring the respective first reference surfaces160, 40 into abutting relationship, move the latch 76 to engage the workcomponent 12 at the first side wall 24, and then move the lever 78 fromthe unlatched to the latched position to draw together and hold inabutting engagement the first guide surface or first reference surface160 of the alignment tool 110 and the first wall surface or firstreference surface 40 of the work component 12. Abutting engagement ofthe respective second reference surfaces 162, 42 may assist in aligningthe components 110 and 12, as may be the case with use of the retentionelement 190 to engage respective third reference surfaces 192. Thebiasing element 80 ensures a firm connection is provided by the latchassembly 70 of the alignment tool 110 and the side wall 24 of the workcomponent 12, although it will be appreciated that the lever and latchor fastener may be configured in a manner that reduces the need for abiasing element, or wherein one or both of the lever or latch isconfigured to deflect in a manner that provides some resilience.

Given that the first guide surface or first reference surface 160 isperpendicular to the respective first and second work piece guidesurfaces GS1′ and GS2′ of the alignment tool 110, the positive abuttingengagement of the first and second reference surfaces 160, 164 of thealignment tool 110 with the respective first and second referencesurfaces 40, 42 of the work component 12 will necessarily result in theextruded track of the work component 12 being precisely perpendicular toeither the first work piece guide surface GS1′ or second work pieceguide surface GS2′. The alignment tool 110 and its respective first andsecond work piece guide surfaces GS1′ and GS2′ also extend beneath thetrack 12, so as to provide elongated first and second work piece guidesurfaces GS1′ and GS2′ for greater accuracy. These features ensure thatwhen either work piece guide surface is placed against an edge of a workpiece, the work component 12 will be precisely perpendicular to the workpiece, so as to provide precise alignment and cutting of the work piece.In addition, the over-center movement of the lever 178 to the closedposition effectively avoids having to account for the problematicinfluences in the prior art, such as tolerances or movements related topositioning or torque applied to fasteners, or loosening of the twocomponents during use, the need to use a separate gage to check andrecheck their alignment, etc.

As with the first example alignment tool 10, it will be appreciated thatthe second example alignment tool 110 of the present disclosure providesfor a method of connecting an alignment tool 110 to a work component 12for use in aligning the work component 12 with a work piece, wherein thework component 12 has at least a first side wall surface 40 extendinglongitudinally in a first direction and at least a T-shaped slot 30spaced apart from the at least first side wall surface 40 and extendinglongitudinally in the first direction. The method comprises the stepsof: holding the alignment tool 110 in a position adjacent an end of thework component 12, wherein the alignment tool 110 includes a body 150having at least a first reference surface 160 extending in the firstdirection, a retention element 190 spaced from the at least firstreference surface 160, at least a first guide surface GS1′ extending ina second direction that is perpendicular to the first direction, and aclamp assembly 70 connected to the body 150; moving the alignment tool110 toward the work component 12 so as to insert the retention element190 into the T-shaped slot 30 that is spaced from the at least firstside wall surface 40 of the work component 12; moving the at least firstreference surface 160 of the alignment tool 110 into a position oppositethe first side wall surface 40 of the work component 12; extending afastener 76 of the clamp assembly 70 in the second direction beyond thefirst side wall surface 40 of the work component 12; moving the clampassembly 70 to engage the first side wall surface 40 of the workcomponent 12 and to draw together and hold in abutting engagement the atleast first reference surface 160 of the alignment tool 110 and thefirst side wall surface 40 of the work component 12.

From the above disclosure, it will be appreciated that alignment toolsfor use with work components may be constructed in accordance with thepresent disclosure and may be provided in various configurations. Anyvariety of suitable materials of construction, configurations, shapesand sizes for the components and methods of connecting the componentsmay be utilized to meet the particular needs and requirements of an enduser. It will be apparent to those skilled in the art that variousmodifications can be made in the design and construction of suchalignment tools, as well as in the method of assembling an alignmenttool to a work component, without departing from the scope or spirit ofthe claimed subject matter, and that the claims are not limited to thepreferred embodiments and methods illustrated herein. The examplealignment tools shown herein may exhibit one or more of theabove-referenced potential advantages, depending upon the specificdesign chosen. It also will be appreciated that the example embodimentsmay be shown in simplified form, so as to focus on the key componentsand to avoid including structures that are not necessary to thedisclosure and that would over complicate the drawings.

1-20. (canceled)
 21. An alignment tool for connection to a workcomponent, comprising: a generally planar body; a retention member thatextends upward from the body; a clamp assembly spaced from the retentionmember and being connected to the body; a first reference surface thatextends upward from the body and is located between the retention memberand where the clamp assembly is connected to the body; the clampassembly having a fastener that extends toward the retention member andpast the first reference surface; and wherein the clamp assembly ismovable to draw a distal end of the fastener in a direction toward wherethe clamp assembly is connected to the body, and the fastener is biasedto move the distal end of the fastener toward the first referencesurface.
 22. The alignment tool in accordance with claim 21, wherein theclamp assembly further comprises a base connected to the body.
 23. Thealignment tool in accordance with claim 22, wherein the first referencesurface extends in a first direction and the base is positioned to havethe fastener extend at an angle relative to the first reference surface.24. The alignment tool in accordance with claim 23, wherein the clampassembly further comprises a biasing element that is connected to thebase and the fastener.
 25. The alignment tool in accordance with claim21, wherein the clamp assembly further comprises a lever and thefastener is a latch, with the latch being connected to the lever. 26.The alignment tool in accordance with claim 25, wherein the clampassembly further comprises a base connected to the body, the lever ispivotally connected to the base and the latch is pivotally connected tothe lever.
 27. The alignment tool in accordance with claim 21, whereinthe work component is a track saw rail for use with a circular saw. 28.The alignment tool in accordance with claim 21, wherein a secondreference surface of the body extends in a second direction.
 29. Thealignment tool in accordance with claim 28, wherein the second referencesurface is adjacent to the first reference surface.
 30. The alignmenttool in accordance with claim 21, wherein the retention element isT-shaped.
 31. The alignment tool in accordance with claim 21, wherein aside of the body comprises a guide surface.
 32. The alignment tool inaccordance with claim 31, wherein the guide surface is at an anglerelative to the first reference surface.
 33. The alignment tool inaccordance with claim 21, wherein the body further comprises at leastone notch that extends inward from a side of the body and permitspassage of a portion of a clamp.
 34. The alignment tool in accordancewith claim 21, wherein the body further comprises at least one openingthat provides for grasping of the alignment tool.
 35. An alignment toolfor connection to a work component and for use in aligning the workcomponent with a work piece, the alignment tool comprising: a bodyhaving a first reference surface that extends upward and in a firstdirection; a retention member that extends upward and is spaced from thefirst reference surface in a second direction; a clamp assemblyconnected to the body and having a fastener that extends in the seconddirection past the first reference surface; and wherein the fastener hasa distal end and the clamp assembly is movable to draw the distal endtoward the first reference surface.
 36. The alignment tool in accordancewith claim 35, wherein the clamp assembly further comprises a base thatis connected to the body, a biasing element that is connected to thebase and the fastener, and the biasing element biases the fastenertoward the base.
 37. The alignment tool in accordance with claim 36,wherein the fastener is a latch and the clamp assembly further comprisesa lever pivotally connected to the base, and the latch is pivotallyconnected to the lever.
 38. The alignment tool in accordance with claim35, wherein the retention member is T-shaped.
 39. The alignment tool inaccordance with claim 35, wherein the work component is a track saw railfor use with a circular saw.
 40. The alignment tool in accordance withclaim 39, wherein the body further comprises a work piece guide surfacethat extends at an angle relative to the first reference surface.